First Artificial Jawbone Created Using 3D Printer

The Functional Morphology Research Group at the University of Hasselt BIOMED Research Institute (Diepenbeek, Belgium) created the artificial jawbone following a magnetic resonance imaging (MRI) scan of the 83 year old female patient’s own diseased mandible, who had to have her entire mandible removed to prevent the spread of osteomyelitis and retain an open airway and basic swallowing and chewing functions. The custom implant was created in just hours using a laser printer spraying titanium powder to create the 3D custom construction, which was then coated with an artificial bone deposit and finally polished before placement.

Developed in collaboration with engineers from the Xios Hogeschool (Limburg, Belgium), Xilloc Medical (Maastricht, The Netherlands) and other institutions, the manufacturing technique is based on dedicated metal additive manufacturing (AM) technology; a high‐precision laser selectively heats titanium metal powder particles, which can quickly and fully melt to properly attach to the previous layer without glue or binder liquid. As layer upon layer is built successively, the technique can be used to print functional implant shapes that otherwise require multiple metalworking steps or it cannot be produced any other way. Cavities in the product facilitate muscle diagastic attachment and in-growth.

The complex implant incorporates articulated and polished joint surfaces and bioceramic coating and was postprocessed with dedicated features, such as provisions to insert dental bar and bridge superstructures at a later date. The surgery, which took place during June 2011, lasted less than four hours, and within one day of the operation the patient had restored facial esthetics and had regained basic speech and swallowing functions. The implant itself, which at approximately 107 grams implant is just a little heavier than a natural jaw, was manufactured by Layerwise NV (Leuven, Belgium), which specializes in AM.

“The new treatment method is a world premiere because it concerns the first patient specific implant in replacement of the entire lower jaw. The implant integrates multiple functions, including dimples increasing the surface area, cavities promoting muscle attachment, and sleeves to lead mandible nerves,” said Prof. Jules Poukens, PhD, of the University of Hasselt, who developed the technology. “Shortly after waking up from the anesthetics the patient spoke a few words, and the day after the patient was able to speak and swallow normally again.”

Related Links:
University of Hasselt BIOMED Research Institute
Xios Hogeschool
Layerwise NV